Wood fastener

ABSTRACT

Fasteners are provided that include a head and having a head, a tip end having a tip, a first body portion having right-hand threads, and a second body portion having left-hand threads. The first body portion is adjacent to the tip end of the fastener and extends a first distance along a length of the fastener towards the head end. The second body portion is adjacent to the first body portion, and extends the head end of the fastener and extending a second distance along the length of the fastener towards the head end. The right-hand threads, and the left-hand threads, can have a pitch angle α of less than about 60°.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 61/309,665, filed Mar. 2, 2010, currently pending.

FIELD OF THE INVENTION

The present technology relates to fasteners and methods of installingfasteners, and particularly fasteners that can be used to secure metalpanels to wood building structures.

BACKGROUND

In the construction industry, post frame metal building materials areattached to the wooden frame structure with various types of woodfasteners. However, current wood fastener thread designs have a tendencyto back-out over time, thus weakening the connection and the building'sstructural integrity. Additionally, known fasteners can have a tendencyto break during installation due to high drive torques in certain highdensity materials, as well as having a tendency to strip-out in certainlow density materials.

SUMMARY OF THE INVENTION

The present technology relates to fasteners and methods of installingfasteners in order to secure metal panels to wood building structures.

In one aspect, a fastener is provided that includes a head and having ahead, a tip end having a tip, a first body portion, and a second bodyportion. The first body portion is adjacent to the tip end of thefastener and extends a first distance along a length of the fastenertowards the head end. The first body portion includes right-hand threadshaving a pitch angle α of less than about 60°. The second body portionis adjacent to first body portion and extends a second distance alongthe length of the fastener towards the head end. The second body portionincludes left-hand threads.

In a second aspect, a fastener is provided that includes a head andhaving a head, a tip end having a tip, a first body portion, and asecond body portion. The first body portion is adjacent to the tip endof the fastener and extends a first distance along a length of thefastener towards the head end. The first body portion includesright-hand threads having a pitch angle α from about 20° to about 40°.The second body portion is adjacent to first body portion and extends asecond distance along the length of the fastener towards the head end.The second body portion includes left-hand threads having a pitch angleα from about 20° to about 40°.

In a third aspect, a method of installing a fastener to secure a metalpanel to a wood structural element is provided that includes the stepsof creating a bur of metal as a tip of the fastener penetrates the metalpanel; causing an area of the metal panel immediately surrounding thefastener to pull away from the wood structural element as right-handthreads on a first body portion of the fastener pass through the metalpanel; contacting the bur of metal with left-hand threads on a secondbody portion of the fastener; removing the bur of metal as the left-handthreads pass through the metal panel; pushing the area of the metalpanel towards the wood structural element; and contacting the woodstructural element with the area of the metal panel prior to the area ofthe metal panel being contacted with the head of the fastener.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific examples have been chosen for purposes of illustration anddescription, and are shown in the accompanying drawings, forming a partof the specification.

FIG. 1 is a side elevational view of one example of a fastener of thepresent technology.

FIG. 1A is a detail view of the area A of FIG. 1.

FIG. 2 is a perspective view of a second example of a fastener of thepresent technology, having a sealing washer assembled therewith.

FIG. 3 is a side elevational view of the fastener of FIG. 2, having asealing washer assembled therewith.

DETAILED DESCRIPTION

Fasteners of the present technology can be used in any suitableapplication, but are most particularly suited to constructionapplications in which metal building materials are secured to wood framestructures.

FIGS. 1, 1A and 2 illustrate examples of a fastener 100 of the presenttechnology. The same reference numbers have been used for aspects thatare the same in each of the illustrated examples. The fastener 100 canbe made of any suitable material, including for example carbon steel.Additionally, the fastener 100 can have a coating, such as a coating toimprove the weather resistance properties of the fastener 100. Afastener 100 can have any suitable length, including but not limited to1 inch, 1.5 inches, 2 inches, 2.5 inches, or 3 inches.

As illustrated in FIGS. 1 and 2, the fastener 100 has a body 102 thatincludes a tip end 104 and a head end 106. The fastener 100 has a point108 at the tip end 104 of the body, and a head 110 at the head end 106of the body. The fastener 100 also has a first body portion 112 that isadjacent to the tip end 104 and includes right-hand threads 114, and asecond body portion 116 that is adjacent to the head end 106 andincludes left-hand threads 118. The head of the fastener 100 can be anysuitable style. The tip end 104 of the fastener 100 can include one ormore partially formed threads 126. The point 108 of the fastener 100 caninclude a sharp, self-tapping point. In the illustrated example, thefastener 100 has a type-17 point, which can allow for desiredpenetration in lapped metal conditions. As illustrated in FIG. 2, asealing washer 132 can be included with, or assembled to a fastener 100.The sealing washer 132 can be any suitable material, such as rubber, andmay be placed on the fastener 100 adjacent to and abutting the head 106.

The first body portion of the fastener 100 is adjacent to the tip end104 of the fastener 100 and extends a first distance D₁ along the lengthof the fastener 100 towards the head end 106. The first body portion 112includes right-hand threads 114. The right-hand threads 114 can besingle or multi-lead threads. The right-hand threads 114 can have anysuitable diameter and number of threads per inch of length along thebody of the fastener. For example, the right-hand threads 114 of theillustrated embodiment are 10-14 threads, having a #10 diameter, whichis a major diameter of about 0.19 inches plus or minus normal ANSItolerances, and about 14 threads per inch. As illustrated in the detailcall-out of FIG. 1A, the right-hand threads 114 have a pitch angle αthat less than standard threads having a 60° pitch angle. For example,the right-hand threads 114 of the fastener 100 can have a pitch angle αthat is from 20° to about 40°.

The pitch angle α of the right-hand threads 114 can have a 0° to 10°/20°to 30° geometric configuration. In such an example, each thread has afirst internal angle β on the tip side 120 of the thread, which facestowards the tip 108 of the fastener 100, and a second internal angle γon the head side 122 of the thread, which faces the head end 110 of thefastener 100. For example, the tip side 120 and the head side 122 ofeach thread slope towards each other from the base of the thread andmeet at a point 124 that is a certain height from the body 102 of thefastener 100. When a vertical reference line B is drawn to the body ofthe fastener from the point 124, the tip side 120 of the thread slopesaway from the vertical reference line at the first internal angle β,which can be from about 20° to about 30°. In such an example, the headside 122 of the thread slopes away from the vertical reference line atthe second internal angle γ, which can be from about 0° to about 10°.For example, the thread pith angle α can be about 30°, with the firstinternal angle β of the tip side 120 being about 20°, and the secondinternal angle γ of the head side 122 being about 10°. In at least someexamples, the geometric configuration of the threads can improve thefastener's resistance to backing out over time after installation.

In some examples, one or more of the first fully formed right-handthreads 114 on the first body portion 112, which are the threads closestto the tip end 104 of the fastener, can include serrations 128. In atleast one example, at least one of the first three fully formedright-hand threads 114 on the first body portion 112, which are thethreads closest to the tip end 104 of the fastener, can includeserrations 128. For example, one, two, or all three of the first fullyformed right-hand threads can include serrations 128. In the examplesillustrated in FIGS. 1 and 2, the first two fully formed threads includeserrations 128. In the example illustrated in FIG. 2, the serrations 128can be teeth 130. Such teeth can be rectangular, as illustrated in FIG.2, or can have any other suitable shape, such as being triangular. In atleast some examples, serrations 128 can reduce the drive torque neededto install the faster 100, and facilitate installation of the fastener100 through knots and hardwood. Additionally, it is common that when afastener pierces metal siding, a bur of metal can be created, which issometimes called a pig-tail. The inclusion of serrations 128 can resultin the bur being removed then the serrated threads contact the bur asthe fastener 100 is being installed.

The second body portion 116 of the fastener 100 is adjacent to the firstbody portion 112 of the fastener 100 and extends a second distance D₂along the length of the fastener 100 towards the head end 106. Inpreferred examples, the length of the second body portion can be lessthan the length of the first body portion. For example, with referenceFIG. 1, the second distance D₂ of the second body portion 116 can beless than the first distance D₁ of the first body portion. In someexamples, such as when the total length of the fastener 100 is about 3inches or less, the length of the second body portion, which is equal tothe second distance D₂ of the second body portion, can be less than orequal to about one quarter of an inch (0.6 cm).

The second body portion 116 includes left-hand threads 118. Theleft-hand threads 118 can be single or multi-lead threads. The left-handthreads 116 can have any suitable diameter and number of threads perinch of length along the body of the fastener. The second body portion116 of the fastener 100 can include any number of left-hand threads,including, for example, from about 1 thread to about 5 threads, orpreferably from about 2 threads to about 4 threads. The left-handedthreads have the same diameter as the right-hand threads, or can beoversized, meaning that the left-hand threads can have a larger diameterthan the right-hand threads. As illustrated in FIGS. 1 and 2, theleft-hand threads the left-hand threads 116 of the illustratedembodiment can be 10-12 threads, having a #10 diameter, which is a majordiameter of about 0.19 inches plus or minus normal ANSI tolerances, andabout 12 threads per inch. In at least some examples when a fastener isbeing installed through metal siding, the left-hand threads can resultin the bur being removed that is commonly created when the fastenerpierces the metal siding. Additionally, the left-hand threads can invertthe edge of the metal around the insertion hole of the fastener 100,which can create a smooth surface and may prevent the metal siding fromcutting and damaging the rubber sealing washer 132. Further, whileright-hand threads tend to back-out over time due to expansion andcontraction of the building materials and the fastener when subjected tovarying weather conditions, the left hand threads can tend to applyforce in opposite direction, resisting back-out,

In at least some examples, the left-hand threads 118 can have the samepitch angle as the right-hand threads. Accordingly, the left-handthreads 118 have a pitch angle α that less than standard threads havinga 60° pitch angle. For example, the left-hand threads 118 of thefastener 100 can have a pitch angle α that is from about 20° to about40°. As discussed above with reference to FIG. 1A, the pitch angle α ofthe left-hand threads 118 can have a 0° to 10°/20° to 30° geometricconfiguration. In such an example, each thread has a first internalangle β on the tip side 120 of the thread, which faces towards the tip108 of the fastener 100, that can be from about 20° to about 30°. Eachthread also has a second internal angle γ on the head side 122 of thethread, which faces the head end 110 of the fastener 100, that can befrom about 0° to about 10°. For example, the thread pith angle α can beabout 30°, with the first internal angle β of the tip side 120 beingabout 20°, and the second internal angle γ of the head side 122 beingabout 10°.

In at least one application, fasteners of the present technology can beused to secure metal panels to wood building structures. One method ofinstalling a fastener 100 of the present technology can include steps ofinserting the fastener through a metal panel and into a wood structuralelement. A sealing washer 132 can be assembled to the fastener 100 priorto inserting the fastener 100 through the metal panel and into the woodstructural element. As with conventional fasteners, the step ofinserting the fastener 100 can include the fastener 100 creating a bur,or pigtail, of metal that is attached to the metal panel as the tip 108of the fastener penetrates the metal panel. Additionally, as also tendsto be observed with conventional fasteners, the step of inserting thefastener 100 can include the right-hand threads of the fastener causingan area of the metal panel immediately surrounding the fastener 100 topull away from the wood structural element, as the right-hand threads114 of the first body portion 102 of the fastener 100 pass through themetal panel. In methods of installing conventional fasteners, creating abur of metal and causing the area of the metal panel immediatelysurrounding the fastener to pull away from the wood structural elementcan each tend to cause damage to the sealing washer.

However, in methods of installing fasteners of the present technology,such damage to the washer may be reduced or prevented. For example, thestep of inserting a fastener 100 can also include the fastener 100removing the bur of metal as it passes through the metal panel. In oneexample, removing the bur of metal can include contacting the bur ofmetal with the left-hand threads 118 on the second body portion of thefastener, and one or more of the left-hand threads detaching the bur ofmetal as the left-hand threads 118 pass through the metal panel. Inanother example, where the fastener includes one or more right-handthreads having serrations 128, removing the bur of metal can includecontacting the bur of metal with the serrations 128 on the one or moreright-hand threads 114, and one or more of the serrations 128 detachingthe bur of metal as the one or more right-hand threads 114 havingserrations 128 pass through the metal panel.

Additionally, in practice, the metal panel can stop pulling away fromthe wood structural element at the junction of the right-hand andleft-hand thread. Once the left-hand threads 118 make contact with themetal panel, the left-hand threads 118 can push the metal panel towardthe wood structural element prior to the fastener being fully inserted,at which point the area of the metal panel would be in contact with thehead 110 of the fastener 100, or with the sealing washer 132 that can beadjacent to and abutting the head 110 of the fastener 100. Accordingly,the step of inserting a fastener 100 can also include pushing the areaof the metal panel, which had been caused to pull away from the woodstructural element, towards the wood structural element, and contactingthe wood structural element with the area of the metal panel prior tothe area of the metal panel being contacted with the head of thefastener or the sealing washer adjacent to the head of the fastener.This may enable the fastener installer to know that the metal panel hasmade contact with the wood structural element prior to the fastenerbeing completely installed. In such instances, the fastener installercan then apply an appropriate final seating torque to the fastener, thusproperly compressing the sealing washer, and preventing the fastener andsealing washer from being over-torqued, which may damage the sealingwasher and result in leaks.

From the foregoing, it will be appreciated that although specificexamples have been described herein for purposes of illustration,various modifications may be made without deviating from the spirit orscope of this disclosure. It is therefore intended that the foregoingdetailed description be regarded as illustrative rather than limiting,and that it be understood that it is the following claims, including allequivalents, that are intended to particularly point out and distinctlyclaim the claimed subject matter.

1. A fastener comprising: a head and having a head; a tip end having atip; a first body portion that is adjacent to the tip end of thefastener and extends a first distance along a length of the fastenertowards the head end, the first body portion including right-handthreads having a pitch angle α of less than about 60°; and a second bodyportion that is adjacent to first body portion and extends a seconddistance along the length of the fastener towards the head end, thesecond body portion including left-hand threads.
 2. The fastener ofclaim 1, wherein the right-hand threads have a pitch angle α that isfrom about 20° to about 40°.
 3. The fastener of claim 1, wherein thepitch angle of the right-hand threads comprises: a first internal angleβ that is from about 20° to about 30°; and a second internal angle γthat is from about 0° to about 10°.
 4. The fastener of claim 1, whereinat least one of the first three fully formed right-hand threads on thefirst body portion includes serrations.
 5. The fastener of claim 1,wherein the second distance of the second body portion is less than thefirst distance of the first body portion.
 6. The fastener of claim 1,wherein the second distance of the second body portion is equal to orless than about one quarter of an inch.
 7. The fastener of claim 1,wherein the left-hand threads have a pitch angle α of less than about60°.
 8. The fastener of claim 1, wherein the left-hand threads have apitch angle α that is from about 20° to about 40°.
 9. The fastener ofclaim 1, wherein the pitch angle of the left-hand threads comprises: afirst internal angle β that is from about 20° to about 30°; and a secondinternal angle γ that is from about 0° to about 10°.
 10. A fastenercomprising: a head and having a head; a tip end having a tip; a firstbody portion that is adjacent to the tip end of the fastener and extendsa first distance along a length of the fastener towards the head end,the first body portion including right-hand threads having a pitch angleα from about 20° to about 40°; and a second body portion that isadjacent to first body portion and extends a second distance along thelength of the fastener towards the head end, the second body portionincluding left-hand threads having a pitch angle α from about 20° toabout 40°.
 11. The fastener of claim 10, wherein the pitch angle of theright-hand threads comprises: a first internal angle β that is fromabout 20° to about 30°; and a second internal angle γ that is from about0° to about 10°.
 12. The fastener of claim 10, wherein at least one ofthe first three fully formed right-hand threads on the first bodyportion includes serrations.
 13. The fastener of claim 10, wherein thesecond distance of the second body portion is less than the firstdistance of the first body portion.
 14. The fastener of claim 10,wherein the second distance of the second body portion is equal to orless than about one quarter of an inch.
 15. The fastener of claim 10,wherein the pitch angle of the left-hand threads comprises: a firstinternal angle β that is from about 20° to about 30°; and a secondinternal angle γ that is from about 0° to about 10°.
 16. A method ofinstalling a fastener to secure a metal panel to a wood structuralelement is provided that comprises the steps of creating a bur of metalas a tip of the fastener penetrates the metal panel; causing an area ofthe metal panel immediately surrounding the fastener to pull away fromthe wood structural element as right-hand threads on a first bodyportion of the fastener pass through the metal panel; removing the burof metal as the fastener passes through the metal panel; pushing thearea of the metal panel towards the wood structural element as left-handthreads on a second body portion of the fastener pass through the metalpanel; and contacting the wood structural element with the area of themetal panel prior to the area of the metal panel being contacted with ahead of the fastener or a sealing washer adjacent to the head of thefastener.
 17. The method of claim 16, wherein the step of removing thebur of metal comprises: contacting the bur of metal with the left-handthreads on the second body portion of the fastener; and detaching thebur of metal as the left-hand threads pass through the metal panel. 18.The method of claim 16, wherein the step of removing the bur of metalcomprises: contacting the bur of metal with one or more right-handthreads having serrations; and detaching the bur of metal as the one ormore right-hand threads having serrations pass through the metal panel.